Maxon RA-35, RA-45 Maintenance Manual

MAINTENANCE MANUAL

RA-35 & RA-45

M-13-03

REV

. C

MAY 2016

© MAXON Lift Corp. 2016

1

1921 Slauson Ave.

Santa Fe Springs, CA. 90670

LIFT CORP.

CUSTOMER SERVICE:

TELEPHONE [phone] TOLL FREE [phone]

FAX: [phone]

NOTE: For latest version of all Manuals (and replacements), download the

Manuals from Maxon’

s website at www.maxonlift.com.

WARRANTY/ RMA POLICY & PROCEDURE

LIFTGATE WARRANTY

Type of Warranty: Full Parts and Labor

Term of Warranty: Standard Liftgates - 2 years from ship date or 6,000 cycles
Premium Liftgates - 2 years from ship date or 10,000 cycles

This warranty shall not apply unless the product is installed, operated and maintained in accordance with MAXON Lift’s speci• cations as set forth in
MAXON Lift’s Installation, Operation and Maintenance manuals. This warranty does not cover normal wear, maintenance or adjustments, damage or
malfunction caused by improper handling, installation, abuse, misuse, negligence, or carelessness of operation. In addition, this warranty does not
cover equipment that has had unauthorized modi• cations or alterations made to the product.

MAXON agrees to replace any components which are found to be defective during the • rst 2 years of service, and will reimburse for labor based on
MAXON’s Liftgate Warranty Flat Rate Schedule. (Copy of the Flat Rate is available at www.maxonlift.com.)

All warranty repairs must be performed by an authorized MAXON warranty facility. For any repairs that may exceed $500, including parts and labor,
MAXON’s Technical Service Department must be noti• ed and an “Authorization Number” obtained.

All claims for warranty must be received within 30 Days of the repair date, and include the following information:

1. Liftgate Model Number and Serial Number

2. The End User must be referenced on the claim

3. Detailed Description of Problem

4. Corrective Action Taken, and Date of Repair

5. Parts used for Repair, Including MAXON Part Number(s)

6. MAXON R.M.A. # and/or Authorization # if applicable (see below)

7. Person contacted at MAXON if applicable

8. Claim must show detailed information i.e. Labor rate and hours of work performed

Warranty claims can also be placed online at www.maxonlift.com. Online claims will be given priority processing.

All claims for warranty will be denied if paperwork has not been received or claim submitted via Maxon website for processing by MAXON’s Warranty
Department within 30 days of repair date.

All components may be subject to return for inspection, prior to the claim being processed. MAXON products may not be returned without prior written
approval from MAXON’s Technical Service Department. Returns must be accompanied by a copy of the original invoice or reference with original
invoice number and are subject to a credit deduction to cover handling charges and any necessary reconditioning costs. Unauthorized returns will be

refused and will become the responsibility of the returnee.

Any goods being returned to MAXON Lift must be pre-approved for return, and have the R.M.A. number written on the outside of the package in plain
view, and returned freight prepaid. All returns are subject to a 15% handling charge if not accompanied by a detailed packing list. Returned parts
are subject to no credit and returned back to the customer. Defective parts requested for return must be returned within 30 days of the claim date for
consideration to:

MAXON’s warranty policy does not include the reimbursement for travel time, towing, vehicle rental, service calls, oil, batteries or loss of income due to
downtime. Fabrication or use of non Maxon parts, which are available from MAXON, are also not covered.

MAXON’s Flat Rate Labor Schedule takes into consideration the time required for diagnosis of a problem.

All Liftgates returned are subject to inspection and a 15% restocking fee. Any returned Liftgates or components that have been installed or not returned
in new condition will be subject to an additional reworking charge, which will be based upon the labor and material cost required to return the Liftgate or
component to new condition.

PURCHASE PART WARRANTY

erm of Warranty: 1 Year from Date of Purchase.

T

Type of Warranty: Part replacement only. MAXON will guarantee all returned genuine MAXON replacement parts upon receipt and inspection of parts
and original invoice.
All warranty replacements parts will be sent out via ground freight. If a rush shipment is requested, all freight charges will be billed to the requesting
party.

MAXON Lift Corp.

10321 Greenleaf A

ve., Santa Fe Springs, CA 90670
Attn: RMA#__

TABLE OF CONTENTS

SUMMAR

WARNINGS & SAFETY INSTRUCTIONS ............................................................................ 6

LIFTGATE TERMINOLOGY .................................................................................................. 8

PERIODIC MAINTENANCE ................................................................................................ 10

PERIODIC MAINTENANCE CHECKS ................................................................................ 10

PERIODIC MAINTENANCE CHECKLIST ............................................................................11

CHECKING HYDRAULIC FLUID ........................................................................................ 12

CHANGING HYDRAULIC FLUID ........................................................................................ 14

PLATFORM GAP & STOP ADJUSTMENT .......................................................................... 16

DECALS .............................................................................................................................. 18

SYSTEM DIAGRAMS ......................................................................................................... 22

PUMP & MOTOR SOLENOID OPERATION ....................................................................... 22

Y OF CHANGES: M-13-03, REVISION C ............................................................. 5

HYDRAULIC SCHEMATIC ................................................................................................. 23

ELECTRICAL SCHEMATIC ................................................................................................. 24

STOW SIGNAL ELECTRICAL SCHEMATIC ....................................................................... 25

TROUBLESHOOTING ........................................................................................................ 26

PLATFORM WILL NOT RAISE & MOTOR WILL NOT RUN ............................................... 26

PLATFORM WILL NOT RAISE, BUT MOTOR RUNS ......................................................... 27

PLATFORM RAISES BUT LEAKS DOWN .......................................................................... 28

PLATFORM RAISES PARTIALLY THEN STOPS ............................................................... 30

LIFTGATE WILL NOT LIFT RATED CAPACITY .................................................................. 32

PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR TOO QUICKLY ............... 34

SUMMAR

PAGE DESCRIPTION OF CHANGE

Y OF CHANGES: M-13-03, REVISION C

COVER

20-75 Removed parts explosion illustrations and parts lists.

25 Revised stow signal electrical schematic to re! ect relay and wire changes.

Updated REV and date of release.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

5

Comply with the following WARNINGS and SAFETY INSTRUCTIONS while maintaining
Liftgates. See Operation Manual for operating safety requirements.

WARNINGS & SAFETY INSTRUCTIONS

•

Do not stand, or allow obstructions, under the platform when lowering the Liftgate. Be sure your

feet are clear of the Liftgate.

• Keep fi ngers, hands, arms, legs, and feet clear of moving Liftgate parts (and platform
edges) when operating the Liftgate.

• Correctly stow platform when not in use. Extended platforms could create a hazard for

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

people and vehicles passing by

• Disconnect Liftgate power cable from battery before repairing or servicing Liftgate.

• If it is necessary to stand on the platform while maintaining the Liftgate, keep your feet and any

objects clear of the inboard edge of the platform. Your feet or objects on the platform can become
trapped between the platform and the Liftgate extension plate.

• Recommended practices for welding on steel parts are contained in the current AWS (American
Welding Society) D1.1 Structural Welding Code - Steel. Damage to Liftgate and/or vehicle, and

personal injury could result from welds that are done incorrectly.

• Recommended practices for welding on aluminum parts are contained in the current AWS
(American Welding Society) D1.2 Structural Welding Code - Aluminum. Damage to Liftgate

and/or vehicle, and personal injury could result from welds that are done incorrectly.

!

WARNING

.

• Welding on galvanized parts gives off especially hazardous fumes. Comply with WARNING decal

on the galvanized part (FIG. 6-1). To minimize hazard remove galvanizing from weld area, provide
adequate ventilation, and wear suitable respirator.

FIG. 6-1

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SAFETY INSTRUCTIONS

• Read and understand the instructions in this Maintenance Manual before performing mainte-

nance on the Liftgate.

• Before operating the Liftgate, read and understand the operating instructions in Operation
Manual.

• Comply with all WARNING and instruction decals attached to the Liftgate.

Keep decals clean and legible. If decals are illegible or missing, replace them. Free replacement

•
decals are available from Maxon Customer Service.

• Consider the safety and location of bystanders and location of nearby objects when operating the

Liftgate. Stand to one side of the platform while operating the Liftgate.

• Do not allow untrained persons to operate the Liftgate.

• Wear appropriate safety equipment such as protective eyeglasses, faceshield and clothing while

performing maintenance on the Liftgate and handling the battery. Debris from drilling and contact
with battery acid may injure unprotected eyes and skin.

• Be careful working by an automotive type battery. Make sure the work area is well ventilated and
there are no ! ames or sparks near the battery. Never lay objects on the battery that can short the
terminals together. If battery acid gets in your eyes, immediately seek " rst aid. If acid gets on your
skin, immediately wash it off with soap and water.

• If an emergency situation arises (vehicle or Liftgate) while operating the Liftgate, release the con­trol switch to stop the Liftgate.

• A correctly installed Liftgate operates smoothly and reasonably quiet. The only noticeable noise
during operation comes from the power unit while the platform is raised. Listen for scraping, grat­ing and binding noises and correct the problem before continuing to operate Liftgate.

• Use only Maxon Authorized Parts for replacement parts. Provide Liftgate model and serial num­ber information with your parts order. Order replacement parts from:

MAXON LIFT CORP. Customer Service

11921 Slauson Ave., Santa Fe Springs, CA 90670

Online: www.maxonlift.com
Express Parts Ordering: Phone [phone] ext. 4345
Email: Ask your Customer Service representative

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

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LIFTGATE TERMINOLOGY

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

WALL MOUNT

UP/DOWN

SWITCH

IN-OUT

SWITCH

UP-DOWN

SWITCH

POWER

P

ACK

FRAME

ASSEMBLY

SAFETY

ARM

HYDRAULIC

DRIVE

MOT

OR

RELEASE

HANDLE

LATCH

LIFT ARM

TILT ARM

SLIDER

ASSEMBLY

FLIPOVER

HYDRAULIC

LOCK

HYDRAULIC

CYLINDER

PLATFORM

RETENTION RAMPS

8

THIS P

AGE INTENTIONALLY LEFT BLANK

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

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PERIODIC MAINTENANCE

PERIODIC MAINTENANCE CHECKS

!

WARNING

Never operate the Liftgate if parts are loose or missing.

NOTE: Make sure vehicle is parked on level ground while performing the maintenance

checks.

Quarterly or 1250 Cycles (whichever occurs fi

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

Check the hydraulic ! uid level in the pump reservoir. Refer to the CHECKING HYDRAULIC
FLUID procedure in the PERIODIC MAINTENANCE section.

If hydraulic ! uid appears contaminated, refer to the CHANGING HYDRAULIC FLUID
procedure in the PERIODIC MAINTENANCE section.

Keep track of the grade of hydraulic ! uid in the pump reservoir and never mix two different
grades of ! uid.

Check all hoses and " ttings for cha" ng and ! uid leaks. Tighten loose " ttings or replace
parts as required.

Check electrical wiring for cha" ng and make sure wiring connections are tight and free of
corrosion. Use dielectric grease to protect electrical connections.

Check that all WARNING and instruction decals are in place. Also, make sure decals are
legible, clean and undamaged.

Check that all bolts, nuts, and roll pins are in place. Make sure roll pins protrude evenly
from both sides of hinge pin collar. Replace fasteners and roll pins if necessary.

rst)

Check for debris and dirt buildup on the slider rollers and rails. Clean out any buildup of dirt
and debris.

CAUTION

Damaged cylinder seals and contaminated hydraulic fl uid can result from painting
the polished portion of the cylinder rod. T
polished portion of the cylinder rod while painting.

Check for rust and oily surfaces on Liftgate. If there is rust or oil on Liftgate, clean it of
Touch up the paint where bare metal is showing. MAXON recommends using the aluminum
primer touchup paint kit, P/N 908134-01.

o prevent damage, protect the exposed

f.

Semi-annually or 2500 Cycles (whichever occurs fi rst)

Visually check the platform hinge pins for excessive wear and broken welds. See PARTS
BREAKDOWN section for replacement parts. Also, do the Quarterly or 1250 Cycles

maintenance checks.

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PERIODIC MAINTENANCE CHECKLIST

NOTE: Make sure vehicle is parked on level ground while performing maintenance

checks.

Quarterly or 1250 Cycles (whichever occurs fi

Check the level and condition of the hydraulic ! uid.

Visually check all hoses and " ttings for cha" ng and ! uid leaks. Tighten loose " ttings or
replace parts as required.

Check electrical wiring for cha" ng and make sure wiring connections are tight and free
of corrosion. Use dielectric grease to protect electrical connections.

Check that all WARNING and instruction decals are in place.
are legible, clean, and undamaged.

Check that all bolts, nuts, and roll pins are in place. Make sure roll pins protrude evenly
from both sides of hinge pin collar

Check for debris and dirt buildup on the slider rollers and rails. Clean out any buildup of
dirt and debris.

Check for rust and oily surfaces on Liftgate. If there is rust or oil on Liftgate or if the
Liftgate is dirty
the paint system CAUTION and recommended touchup kit on the preceding page.

, clean it off. Touch up the paint where bare metal is showing. Refer to

. Replace fasteners and roll pins if necessary.

rst)

Also, make sure decals

Semi-annually or 2500 Cycles (whichever occurs fi rst)

V

isually check the platform hinge pins for excessive wear and broken welds.

Do the Quarterly or 1250 Cycles Checks on this checklist.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

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